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Authored by Isabel McCord

Enhancing Extruder Performance: Key Products and Maintenance Tips

Optimizing your plastic extruder’s performance is essential for efficiency and reliability. By using the right components and following a robust maintenance schedule, you can improve your extrusion process while minimizing downtime. Here are the essential products and maintenance practices to consider.

Key Products for Extruder Efficiency

Heater Bands:

• Ceramic Heater Bands: Offering excellent heat transfer and durability, ceramic heater bands ensure uniform and reliable heating in critical extrusion zones. Their robust design also reduces the likelihood of heat loss, promoting energy efficiency.
• Maxiband Heaters: Designed as Heat and Cool, Heat Only, or Cool Only. The channels in the extruded aluminum track are precisely sized to accept a .315-diameter tubular heating element and provide an excellent heat sink for rapid heat transfer and good temperature uniformity.

Sensors:

• Thermocouples: Precise temperature monitoring is essential for maintaining optimal extrusion conditions. Thermocouples deliver accurate, real-time temperature readings, enabling fine control over the heating process.
• Pressure Sensors: These sensors monitor material flow, helping to detect blockages or inconsistencies in material feed. By addressing pressure fluctuations early, you can avoid material waste and equipment strain.

Additional Products:

• Extruder Screws: High-quality screws optimize material flow, improving efficiency and product quality.
• Cooling Systems: Effective cooling systems help regulate the temperature of extruded materials, preventing warping, deformation, or other quality issues caused by overheating.

Best Practices for Maintenance

1. Regular Cleaning
   Prevent buildup with Dyna-Purge to maintain smooth operation and reduce costly downtime. Dyna-Purge is an effective cleaning agent that clears residue on the first pass, Dyna-Purge minimizes downtime and reduces plastic scraps. Its ready-to-use formula requires no soaking or mixing and works at the machine’s normal temperature and speed, ensuring no hidden costs. Safe for both operators and equipment, it is heat-stable, non-abrasive, and environmentally compliant.
2. Temperature Control
   Maintaining proper temperature settings is key to producing consistent material quality. Ensure that temperatures are neither too high nor too low to prevent material degradation or production defects.
3. Lubrication
   Following the manufacturer’s lubrication guidelines is essential for reducing friction, wear, and tear on moving parts. Proper lubrication helps extend the lifespan of your extruder.
4. Routine Inspections
   Regularly inspect your extruder for unusual sounds, vibrations, or other warning signs of mechanical issues. Addressing potential problems early prevents costly repairs and production delays.
5. Proper Shutdown
   Adhere to recommended shutdown procedures to protect your extruder and ensure smooth restarts.

Conclusion  

Using the right components, such as heater bands, sensors, and Dyna-Purge, paired with regular maintenance, will ensure optimal performance of your extruder. Regular cleaning, lubrication, and inspections help minimize downtime and keep your extrusion process running smoothly.

Authored by Isabel McCord

Plastic extrusion is a pivotal process in the manufacturing of various plastic products, from pipes and sheets to complex profiles and films. The efficiency and quality of the extrusion process largely depend on two critical factors: temperature and pressure. Managing these parameters effectively ensures the production of high-quality plastic products, minimizes waste, and enhances overall operational efficiency.

Imagine plastic extrusion as a finely tuned engine—temperature and pressure are the heat and torque that keep everything running smoothly. Just like in a high-performance machine, getting the balance right between these two factors is what drives quality and efficiency. Mismanage either, and you’re left with sputtering output, wasted resources, and a lot of headaches.

The Importance of Temperature in Plastic Extrusion

Temperature is the heat under the hood that makes everything run. Too hot, and you risk overheating; too cold, and nothing moves. In extrusion, maintaining the right temperature ensures that your polymer flows like a well-oiled machine, ready to be shaped into the perfect product.

1. Optimal Melt Temperature: Each type of plastic has an optimal melt temperature range. Maintaining the correct temperature ensures that the polymer flows smoothly through the extruder, reducing the risk of defects like bubbles, uneven thickness, or incomplete filling of molds. Just like engines require different grades of fuel, polyethylene needs lower heat compared to polycarbonate, so the temperature settings for extrusion need to be carefully calibrated.
2. Zoning and Gradients: Think of your extruder as a multi-stage turbocharger, with each heating zone playing its part in boosting the melt. These zones help in gradually melting the plastic, ensuring a consistent flow. The right temperature gradient across these zones ensures smooth acceleration without thermal degradation or incomplete melting—just like keeping your turbo running at peak efficiency.

Products for Temperature Control:

• Temperature Sensors: These are the gauges on your dashboard, giving you real-time data to keep everything in check. Whether it’s a thermocouple or an RTD, precise sensors are essential to avoid any redlining.
• Heaters: Depending on the material and application, different types of heaters, such as infrared heaters, cartridge heaters, or band heaters, are used to achieve and maintain the desired temperature. These components are your spark plugs—reliable and efficient, ensuring that your extrusion process fires on all cylinders.

The Role of Pressure in Plastic Extrusion

If temperature is the heat, pressure is the torque. It’s the force that pushes your product through the die, shaping it with precision. Without the right pressure, your operation stalls out, but with too much, you risk blowing a gasket.

1. Die Pressure: Think of this as the gear ratio—too low, and your product won’t take shape; too high, and it swells out of control. Precision here ensures your product is dense and dimensionally accurate, just like shifting gears at the perfect RPM.
2. Back Pressure: Back pressure is the resistance encountered by the plastic as it moves through the screw and towards the die. Back pressure is like tuning your exhaust system—necessary for optimal performance, but too much can create unwanted strain. Managed properly, it ensures your plastic is uniformly melted and mixed, delivering consistent results without overloading your extruder.

Products for Pressure Control:

• Pressure Controllers: These are like torque converters, ensuring smooth and controlled power transfer throughout the process. Advanced pressure controllers keep your extrusion line running efficiently, preventing hiccups and stalls. These controllers often work in conjunction with pressure sensors to provide real-time feedback, ensuring optimal pressure conditions throughout the process.
• Rupture Plugs: These safety devices are your pressure relief valves, stepping in when things get too intense. They protect your equipment by providing a controlled release, keeping everything running smoothly under the hood.

Balancing Temperature and Pressure for Optimal Extrusion

Achieving the perfect balance between temperature and pressure is crucial for the success of the plastic extrusion process. Get the balance right, and you’ll hit that sweet spot where quality, efficiency, and performance come together. If the temperature is too low, you’ll need more pressure to maintain flow, like having to downshift on a steep incline. Conversely, too much heat or pressure can lead to breakdowns, much like overworking an engine. By utilizing precise temperature sensors, reliable heaters, advanced pressure controllers, and safety devices like rupture plugs, manufacturers can optimize their extrusion processes, reduce downtime, and produce high-quality plastic products that meet industry standards.

 

Southern Heat Corporation offers a comprehensive range of products designed to meet the exacting demands of plastic extrusion. From top-notch temperature sensors to robust pressure controllers and rupture plugs, our solutions are engineered to help you achieve unparalleled control and consistency in your extrusion operations.

For more information on our products and how they can enhance your extrusion process, contact Southern Heat Corporation today.

Authored by Isabel McCord

Plastic extrusion, a cornerstone of modern manufacturing, has long relied on cooling systems to maintain optimal processing temperatures and prevent overheating. Traditionally, water has been the go-to coolant. However, a growing trend towards air cooled systems is reshaping the industry. These systems are self-contained and can be supplied as turnkey ready-to-go, requiring minimum labor and installation cost, while drastically reducing downtime and maintenance upkeep compared to conventional liquid cooling. Let’s explore these cooling methods and uncover why the shift is taking place.

Why Air Cooling is a Game Changer:

Simplicity and Maintenance: Air cooling systems are remarkably straightforward to install and maintain. Say goodbye to clogged cooling tubes, the hassles of pumps, filters, coolant treatments, plumbing, and ASCO valves. With air cooling, you’ll enjoy reduced downtime and lower operational costs.

Safety First: Water and electricity don’t mix. Water leaks can lead to significant equipment damage and electrical hazards. Air cooling eliminates these concerns, ensuring a safer working environment.

Consistent Temperature Control: Air cooling often provides superior temperature control compared to water cooling, thanks to direct heat transfer between the barrel and the air. This results in improved product quality, reduced scrap rates, and enhanced process efficiency.

Energy Efficiency: While air-cooling systems require energy to operate the fans, their overall energy consumption is often lower than that of water-cooling systems, which need energy for pumping, coolant treatment, and chiller/heat exchanger operation.

Environmental Impact: Air cooling has a smaller environmental footprint. It reduces water consumption, eliminates the need for water treatment, and lowers your carbon footprint.

Cost Savings: The elimination of plumbing, ASCO valves, leaks, chillers, and heat exchangers results in significant cost savings over time.

Types of Air Cooling:

Cool-to-the-Touch Dual-Layer Shrouds: Designed with safety in mind, these shrouds feature a two-layer construction:

• Inner Layer: Constructed from solid stainless steel, this layer acts as a thermal barrier and directs airflow over the heater.
• Outer Layer: Also made from stainless steel, but perforated to allow maximum heat dissipation while remaining cool to the touch.

Multi-Versal Single-Layer Shroud: This highly adaptable single-layer shroud is ideal for both retrofit and new applications, regardless of the type of barrel band heater used.

• Solid Stainless-Steel Layer: Functions as a radiation shield, directing cooling airflow over the heater.
• Mounting Options:
  • Hinge with Barrel Clamps: Designed for easy installation.
  • Two Individual Halves with Barrel Clamps (Two-Piece): Perfect for installations where space is tight or mounting is challenging.

Arctic Cast Single Layer Shroud: Built for durability, this rugged shroud design is recommended for environments where the shroud system may be exposed to physical damage, such as low extruder barrel installations.

• Vented 1/4″ Thick Cast Aluminum Layer: Directs cooling airflow over the heater.
• Two-Piece Design: Consists of two individual halves bolted together and clamped around the finned cast heater.

Forced Air Blowers: These fans push air over the shroud to facilitate cooling. There are different types to suit various needs:

• Low Profile Single Phase Centrifugal Blowers: Compact and perfect for limited space.
• Standard Single-Phase Centrifugal Blowers: The most common type, offering a balance of performance and size.
• Universal Three-Phase Centrifugal Blowers: More powerful and versatile, suitable for high-output or demanding applications.
• Custom Blower Extensions: Additional components to modify blower performance, such as increasing airflow, reducing noise, or adapting to non-standard mounting locations.

Air Cooled Conversion – PDF

Customer Insights:

“Two years ago…I converted a Welex 4.5 and 3.5-inch co-extrusion line running ABS at approximately 2000 lbs/hr from water-cooled heating jackets to Tempco “cool to the touch” air-cooled finned heaters. I have since converted another same-size co-extruder line. We have been very well pleased with the performance of the Tempco heaters.

The benefits gained are many fold: No valves, No pumps, No tubing, No fittings, No piping, No manifolds, No heat exchanger, No deionized water, No Water Leaks, No rust, No water on the floor, No Guessing

Temperature stability greatly improved the overall process stability…the energy efficiency must be a good deal better, first after two years my two compression zones show the largest on time of 85% and 45% the other.”

Conclusion

While the initial investment in an air-cooling system may be higher, the long-term savings in maintenance, energy consumption, and reduced downtime often outweigh the upfront costs. Embracing air cooling technology is a strategic step towards a more efficient, safe, and sustainable extrusion process.

Considering the benefits of air cooling? Southern Heat can help you transition smoothly from water-based systems to an air-cooled shroud system. Our team of experts will assess your needs and recommend the most suitable air-cooling solution for your extrusion process.

Contact one of our knowledgeable sales engineers today to discuss your requirements. We’re here to answer your questions and guide you through the process.

 

Authored by Isabel McCord

The Four Components of the Thermal Loop

In the world of plastics manufacturing, the thermal loop stands as a critical process, directly influencing product quality, production efficiency, and overall process stability. With its four interconnected components, the thermal loop ensures precise temperature control throughout the entire production cycle. Let’s dive into the components of the thermal loop and meet the key players: sensors, controllers, switches, and electric heaters.

1. Sensors: The Temperature Detectives

Imagine tiny temperature detectives – thermocouples and RTDs (temperature-sensing resistors) – stationed throughout the process, constantly monitoring the material and machinery. These sensors are the eyes and ears of the thermal loop, providing real-time updates on temperature to the control center.

• Thermocouples: Made of two different metals joined at one end, thermocouples generate a voltage proportional to the temperature difference when exposed to heat. Their responsiveness to rapid temperature changes makes them ideal for injection molding, where precise and quick temperature measurement is crucial for achieving the desired shape and surface finish of plastic part
• RTDs: Made of a pure metal (typically platinum), exhibit a predictable change in electrical resistance with temperature. RTDs offer exceptional accuracy and stability over a wide temperature range, making them perfect for demanding applications where precision is paramount. For instance, in extrusion processes, RTDs help maintain consistent material flow and prevent defects like under- or over-extrusion.

 

2. Controllers: The Masterminds

Meet the masterminds behind the scenes – temperature and pressure controllers. These high-tech brains process the data from the sensors and make split-second decisions to adjust the heating or cooling systems. Think of them as the conductors of a symphony orchestra, ensuring every instrument (or heating element) plays its part perfectly.

• Temperature Controllers: These diligent overseers compare the actual temperature to the desired setpoint and adjust the heating or cooling elements accordingly. Using control algorithms like PID (Proportional-Integral-Derivative), they optimize temperature stability and response time. In thermoforming, precise temperature management controlled by temperature controllers is crucial for creating accurate and durable plastic products.
• Pressure Controllers: Maintain the system within safe and efficient operating limits. They regulate the flow of materials or gases to ensure consistent pressure levels, preventing fluctuations that could impact product quality or equipment performance. Pressure controllers play a vital role in injection molding, ensuring even distribution of molten plastic within the mold cavity.

 

3. Electric Heaters: The Muscle

Electric heaters are the muscle of the thermal loop, converting electrical energy into thermal energy to heat the plastic material. Let’s delve deeper into some of the most common types:

• Cartridge Heaters: Cartridge heaters are cylindrical heating elements inserted into drilled holes in the equipment. They offer precise heat delivery and are available in various lengths, diameters, and wattages.
  • Advantages: Compact size, precise heat control, and easy installation.
  • Applications: Commonly used in molds, dies, and extrusion equipment for localized heating.
  • Types: Stainless steel, copper, and sheathed cartridges, with different wattage densities and temperature ratings.

• Band Heaters: Band heaters are flexible heating elements that wrap around cylindrical surfaces, providing even heat distribution. They are available in various widths, lengths, and voltages.
  • Advantages: Versatility, easy installation, and even heat distribution.
  • Applications: Commonly used in extrusion barrels, pipes, and hoses for maintaining consistent temperatures.
  • Types: Mica band heaters, ceramic band heaters, and mineral insulated band heaters.

• Cast-In Heaters: Cast-in heaters are embedded directly into the equipment, offering superior heat transfer and durability. They are typically made of aluminum, bronze, or iron and can be customized to fit various shapes and sizes.
  • Advantages: Excellent heat transfer, long lifespan, and resistance to harsh environments.
  • Applications: Commonly found in extrusion barrels, hot runner systems, and other applications requiring consistent and reliable heating.
  • Customization: Cast-in heaters can be tailored to specific heat output, shape, and mounting requirements.

• Infrared Heaters: Infrared heaters use radiant energy to transfer heat to the target material. They offer precise heat control and rapid heating times.
  • Advantages: Non-contact heating, fast response times, and energy efficiency.
  • Applications: Widely used in preheating, drying, curing, and forming processes.
  • Types: Ceramic infrared heaters, quartz infrared heaters, and shortwave infrared heaters.

• Tubular Heaters: Tubular heaters are cylindrical heating elements composed of a resistance wire encased in a metal sheath. They are versatile and find application in various heating processes.
  • Advantages: Even heat distribution, durability, resistance to corrosion, customizable shapes and sizes.
  • Applications: Heating liquids and gases, Mold heating, Plastic extrusion, Chemical processing.
  • Types: Straight tubular heaters, U-shaped tubular heaters, Immersion tubular heaters

• Strip Heaters: Strip heaters are flexible heating elements that can be easily installed on various surfaces. They come in different widths, lengths, and wattages to accommodate diverse heating needs.
  • Advantages: Versatility, easy installation, and precise temperature control.
  • Applications: Used in molds, platens, and other equipment requiring localized or uniform heating.
  • Types: Silicone rubber strip heaters, finned strip heaters, and mica strip heaters.

4. Switches: The Power Players

Switches are the power players in the thermal loop, controlling the flow of electricity to the heating elements.

• Solid-State Relays (SSRs): These use semiconductor components to switch electrical loads on and off without any moving parts, resulting in lightning-fast response times, high reliability, and long lifespans, making them the preferred choice for demanding applications.
• Mercury Relays: While gradually being phased out due to environmental concerns, mercury relays have been workhorses in the industry for decades. They offer exceptional durability and the ability to handle high current loads, making them suitable for heavy-duty applications.

Conclusion

The beauty of the thermal loop lies in the seamless collaboration of these components. Sensors gather vital temperature data, controllers make informed decisions, switches deliver the power, and heaters provide the heat. It’s a well-orchestrated dance that results in consistent product quality, maximum efficiency, and reduced energy consumption. By understanding the role of each component and how they work together, plastics manufacturers can fine-tune their thermal processes for optimal performance.

Our experienced sales engineers would be happy to assist you in selecting the right components for your thermal loop.

Contact us today for more information!

History of Southern Heat Corporation

Founded in 2005 by Tony Evans and Jason Reed, Southern Heat Corporation has grown from humble beginnings to become a leading manufacturer and distributor of high-quality process heating products. The journey of these two fraternity brothers and best friends, who met at Kennesaw State University while pursuing Engineering degrees, is a testament to their dedication and vision.

The Early Days

After graduating, Tony and Jason were both hired by a company providing maintenance, repair, and operations (MRO) supplies to the plastics industry. After eight years of experience in the industry, they were inspired to start their own business with a clear mission:

• Treat customers according to the golden rule
• Treat employees like family
• Only sell products that allow us to sleep well at night
• Make lots of sales calls

With the expertise of Tony’s wife, Dede Evans, a business accountant and consultant, Southern Heat Corporation was incorporated on August 8, 2005, in a basement in Cartersville, GA. Despite the chaos of running a business from a basement, the company experienced exponential growth, prompting a move to its current location in Cartersville, GA, in 2006.

Growth and Development

As Southern Heat Corporation expanded, more employees were hired, and the product line grew. The company prides itself on the family-like atmosphere it has built, attributing its success to a team effort. Today, Southern Heat Corporation continues to thrive, offering a wide range of products and services.

Products and Services

Today, Southern Heat Corporation is a leading distributor of:

• Electrical Heaters
• Thermocouples
• Process Controllers
• Power Controllers
• Pressure Transducers
• Rupture Disks
• Insulation Blankets
• Accessories and More

The company’s primary focus is on the plastics industry, but it also engages in process heating projects across various industries. Southern Heat Corporation is dedicated to improving customers’ bottom lines by supplying high-quality products at competitive prices.

Commitment to Innovation

As innovators in the field, Southern Heat Corporation stays at the forefront of technological advancements to meet the evolving demands of its customers. The company delivers cost-effective and efficient solutions for process heating requirements, pioneering new developments in heater technology.

Why Choose Southern Heat Corporation?

• Expertise and Experience: Over 20 years of experience in the industry.
• Customer-Centric Approach: Committed to treating customers and employees with the utmost respect and care.
• High-Quality Products: Only sells products that meet stringent quality standards.
• Comprehensive Solutions: A full-service provider of total heating solutions.
• Innovative Technology: Leading the way in heater technology and process heating solutions.

Contact Southern Heat Corporation

For all your process heating needs, trust Southern Heat Corporation to deliver the best and most cost-effective solutions. Whether you are in the plastics industry or another vertical market, we are here to help.

Reach out to us today and experience the difference that comes with working with a company dedicated to excellence, innovation, and customer satisfaction.